BRISTERS Chuck Wagon User manual

Brister’s Utility Vehicles

2 Wheel & 4 Wheel Drive Models

Operator’s Manual

Copyright

January 1, 2007

DIN EX

Section 1 Introduction pages 3-4

Serial Number Plate Location page 4

2 10 Section Safety pages 5-

Pre-Delivery Steps page 9

page 66

Warrant ate

Dealer Inspection Checklist page 10

ection 3 Assembly Instructions pages 11-13 S

Seat Back, Brush guard, Bumper page 12

Steering wheel page 12

Cargo Bed page 13

Seat Base page 13

Section 4 Operating Instructions page 14

Section 5 Maintenance pages 15-22

Fuel Valve Lever page 15

Air Cleaner Page 16

Engine Oil page 17

Transaxle Oil page 18

Drive Belt page 19

Section Troubleshooting pages 20-28 6

Troubleshooting Chart page 26

ection 7 Parts Diagrams pages 29-64 S

Wiring Diagram page 30

11hp 2 wheel drive pages 31-42

265cc 2 wheel drive pages 43-53

13hp 4-wheel drive pages 54-64

arranty Policy page 65 W

Contact Information

y Registration Certific page 67

2

Section 1 Introduction

Brister’s welcomes you to its growing family of new

product owners. This Brister Utility Vehicle UTV is a

light utility vehicle that has been designed with care

and built by skilled workers using quality materials.

Proper set-up, maintenance and safe operating

practices will help you get years of satisfactory use

from this vehicle.

Safety First

Brister’s is fully aware of the need for safe operating

procedures around all of our equipment. We hope yo

will make a sincere effort to put safety above a

u

ll other

riorities. The Brister Utility Vehicle was designed and

pared to instruct you in the

al

end each section in this

anual to develop an understanding of your vehicle and

a

The Operator’s Section is designed to help familiarize

intenance. Read this manual

the recommendations to help ensure safe

and efficient operation.

* The information contained within this manual was

current at the time of printing. Some parts may change

slightly to assure you of the best performance.

* To order a new Operator’s or Parts Manual contact

thorized dealer.

p

built for work, recreation, and enjoyment; however,

improper and irresponsible operation could result in

serious injury or death. Since this is an off-road vehicle,

operators will seldom see the road safety and warning

signs they are accustomed to seeing on highways and

public streets. This places additional responsibility on

the driver to operate this vehicle well within the safe

operational limits and capabilities of the unit.

This manual has been pre

safe and responsible operation of your Brister Utility

Vehicle. Read and abide by all safety alert information

about this vehicle. If you do not understand any part of

this manual, contact your local dealer for additional

information and clarification. As the operator of this

iece of equipment, you are in complete control. Only p

you can prevent an accident from happening.

Using This Manual

* Prior to any vehicle operation it is absolutely essenti

that you read and compreh

m

for your safety. After reviewing this manual, store it in

dry and easily accessible place for future reference.

*

you with safety, assembly, operation, adjustments,

troubleshooting, and ma

and follow

y

our au

Brister’s Design & Manufacturing Co. LLC

Toll Free PH: 1-866-646-5278

d,

y

n,

rear differential.

lso unlike an ATV’s one person “straddle saddle” seat,

e Brister Utility Vehicle sports dual headrest

ushioned seats with seat belts mounted in a highly

gers

shing water and mud. The Brush Guard Bar

Fax: 1-866-329-5278

www.bristers.com

Terminology

Right-hand and left-hand as used in this manual are

determined by facing the direction the vehicle will travel

while in use unless otherwise stated.

Getting Acquainted with your Utility Vehicle

This off-road utility vehicle is a very unique vehicle

designed exclusively for off-road use. It is not designe

properly equipped, or licensed to be safely operated on

public streets and highways. This vehicle is designed to

carry two people and a limited amount of gear or cargo

comfortably and safely over rough terrain that was onl

accessible by ATV’s in the past.

Unlike ATV’s that have handlebar steering, Brister Utilit

Vehicle’s have a steering wheel with easy handling

rack-and pinion steering. The steering’s tight turning

radius makes this vehicle more maneuverable than

most ATV’s. Its four wheeled independent suspensio

large diameter hi-flotation tires and high center-frame

ground clearance adds up to excellent stability and a

smooth ride over rough terrain. Outstanding two

wheeled rear traction drive is achieved by using

premium off-road ATV type tires in tandem with the

engine mounted directly in front of the

A

th

c

styled and protective full length body. Two passen

can ride comfortably in this vehicle protected from

spla

mounted to the vehicle’s frame provides protection

against low hanging limbs and briars.

3

Section 1 Introduction

Always use the serial and model number when ord

arts r your Brister Utility Vehicle. The serial-num

ering

fo ber

The Brush Guard Bar also provides a mounting system

for Brister’s optional windshields, canopy tops and

weather enclosures. It also serves as a mounting base

for many other optional cargo racks, gun and bow racks

The cargo bed is for transporting accessories such as

camping equipment, tree stands, hunting gear, and

fishing gear. A standard hitch moun

.

ting plate enables

uick installation of a rear hitch for pulling small trailers

an

ll

and narrow stance also

nables this vehicle to be loaded in the back of most full

ransport.

is

ards.

ed by the owner

nd the Warranty Registration card should be filled out

sary to provide you with quality

customer service.

T

have been spec

replaced with g

If customer service or repair parts are required contact a

Brister’s dealer. They have trained personnel, genuine

repair parts and equipment specially designed to repair

Brister’s products.

Product Support

Brister’s Design & Manufacturing Co. LLC

P.O. Box 649

Roseland, LA 70456

Toll Free PH: 1-866-646-5278

Fax: 1-866-329-5278

[email protected]

p

plate is located under the cargo bed on the driver’s side

just above the engine, on the frame as shown in figure 1

below.

q

full of supplies, tools, gear, and game.

The Brister Utility Vehicle has some similarities to

ATV. Like an ATV the Brister Utility Vehicle has a short

wheelbase, narrow stance, and high center clearance a

which provide for narrow and difficult trail access. This

combination of short wheelbase

e

to mid-sized pickups for t

The Brister Utility Vehicle’s ground compaction and is

very gentle on the ground and surrounding vegetation.

The highly energized four wheeled independent

suspension system provides an incredibly soft ride and

outstanding stability over difficult terrain. The engine

EPA certified and meets California Air Resources Board

ARB) certification (C stand

Owner Assistance

The safety information should be view

Serial Number Plate Location

_________________

Your Brister’s dealer ur

f this

r you’re not satisfied with the service received,

t e the llowing actions.

Discuss the matter with your dealership service

manager. Make sure they are aware of any problems so

they can assist you.

If you are still unsatisfied, seek out the owner or general

manager of the dealership.

For further assistance write to

Figure 1

Record your Brister Utility Vehicle serial number here for

quick reference:

a

by the dealer at the time of purchase. The owner, upon

purchasing the vehicle, should have participated in a

short drivers training course with the dealer. This

information is neces

Model Number:___________________________

Serial Number:___________

he parts on your B le Utility Vehicle rister Utility Vehic

designed and sho

wants you to be satisfied with yo

ou do not understand any part o

ially uld only be

enuine Brister’s parts.

new vehicle. If y

manual o

please ak fo

4

Read These Important Rules for Safe Operation

Note: The Operator, Passenger, Parent or Guardian must read, study and understand all the items contained

within this owners/operators manual before operating utility vehicle. Failure to follow these instructions

could endanger the personal safety of the Operator, Passenger and any Bystanders.

Close adult supervision is required at all times!

Pay close attention to all Caution and Warning labels

Located on the Utility Vehicle

*IMPORTANT*

When transporting any Brister Utility Vehicle with an installed windshield or

Color matched top DO NOT reach high speeds!

Assumption Of Risk

The owner or operator assumes all the risks incident to or arising out of the operation of

this Utility Vehicle

Failure to follow and comply with all warnings may

cause serious injury or death

5

Section 2 Safety

It is very important to read, understand, and follow all

instructions and warnings located on the decals on your

rister Utility Vehicle. B

6

Section 2 Safety

Safe Operating Procedures

oncern to

ll consumers. Your Brister Utility Vehicle has been

uld operate this vehicle before carefully

ading this Operator’s Manual. Also read all

Keep all bystanders away from this vehicle during

his vehicle who has

ot fully read and comprehended this manual and who

epair all damages and defective parts before

utting vehicle back in to service.

one under 16 years of age to operate

is vehicle.

Operator must always use both hands on the steering

No riders allowed except in factory designed and

Operate this vehicle from the driver’s seat only.

with engine

nning.

vehicle as serious injury or

eath could occur.

and belts exposed.

ey are hot.

* Keep hands, feet, long hair, clothing, and jewelry away

from moving parts and obvious pinch points to avoid

getting caught.

* Wear snug-fitting clothing to avoid entanglement with

moving parts.

The safe operation of any machinery is a big c

a

designed with many built-in safety features. However,

no one sho

re

instructions noted on the safety decals.

* Be familiar with all functions of this vehicle.

*

operation.

* Do not allow anyone to operate t

n

has not been properly trained in the safe operation of

this vehicle.

* Do not operate a vehicle with damaged or defective

parts. R

p

* Do not allow any

th

*

wheel.

*

supplied seating.

*

* Do not leave this vehicle unattended

ru

* Do not dismount a moving

d

* Always operate vehicle with belt guard installed. Do

not leave pulleys

* Do not touch engine, engine exhaust pipe and/or

muffler while th

* Some conditions may warrant extra safety gear to be

orn such as safety helmets and/or goggles. w

Keep hands, arms, feet and all bodily a* ppendages

d tree limbs and brush

ill

f

.

of control may result.

evice to

e.

bject causing serious injury

ull gently. Always stay clear of the

go

nd.

ever make turns at full speed. Reduce

peed when turning empty and reduce speed even

safely inside the confines of the vehicle.

Always be aware of and avoi*

that have a potential of hitting and/or poking individuals

riding the vehicle. Serious body harm could result.

* Avoid sudden stops, starts, and turns.

* Always operate your vehicle at a safe speed that w

allow you to maintain control.

* Operator and passenger are responsible for deciding i

their situation warrants using seat belts.

* Do not exceed total payload capacity of this vehicle

* Do not pull a trailer or implement exceeding 1100

ound towing capacity or lossp

Do not attach an implement, trailer or other d*

the hitch that will produce negative tongue weight.

* Follow all towing instructions in this manual when

towing the UTV behind another vehicle. Do not tow

vehicle faster than 25 MPH.

Do not use the vehicle as an anchor devic*

* Beware, tow ropes, cables and chains can break when

ulling another vehicle or op

or death to anyone in line with the whipping action

created when they break. Never jerk when pulling,

lways ease into a pa

tow line. Never be in line with the tow line.

* Reduce speed when loaded with cargo. Heavy car

load takes longer to stop.

* Reduce speed and payload on hilly, rough, wet, slick

r unstable grouo

* Always make turns at a speed that will maintain control

f vehicle. No

s

7

more when turning loaded with cargo or when pulling a

cargo load. The heaver the cargo load, the slower the

rn should be.

all gear or cargo is properly secured and

ed down.

s.

tal on this vehicle.

latform to

e vehicle.

quipment. Rollover could result from such loading.

rtified ROPS (Roll Over

rotection System). Always avoid rollovers.

traffic.

the

. Never

afe

Never use vehicle for racing and never modify the

rectly and indirectly affected by

e modification.

f all

personnel

round vehicle and especially location of small children.

Always park on level ground, stop engine, set parking

k tires if condition warrants.

u are sure trail

resting hills or going

ver bumps.

top, start suddenly or over accelerate on hills.

oss of control and rollover could result.

ing

nd tractive

apabilities are greatly diminished.

teeper.

ay occur.

control.

When crossing a slope on soft terrain, turn the front

avel.

free wheel in neutral or

ss of control may result.

engage the foot brake and back slowly

own the hill maintaining a straight downhill line of

ts

in

Avoid water crossings when possible and never cross

r

d waterways

rodes shore line and damages water-born habitat. If

designed as

usher bars. Do not attempt to push other vehicles or

When refueling use an (UL) approved non-metallic

t the container

n the ground before fueling to eliminate static

lectrical devices including cell

hones while refueling.

tu

* Make sure

ti

* Do not exceed 400 lbs. in cargo bed area, or 900 lb

to

* Do not mount a receiver hitch type carrier p

th

* Do not load the Brush Guard Bar with heavy

e

* The Brush Guard Bar is not ce

P

* Do not operate this vehicle on highways, public roads,

or where it may be a hazard to faster moving

* Do not operate this vehicle while drinking or under

influence of alcohol and drugs.

* Never attempt wheelies, jumps, or other stunts

drive recklessly. Always operate your vehicle at a s

speed that will allow you to maintain control.

*

engine to exceed 25 MPH vehicle speed.

* Never modify any parts on the vehicle without

authorization. Unauthorized modifications will void

warranty to all parts di

th

* Always make sure the vehicle pathway is clear o

objects when backing up. Know location of

a

Take extra precautions when rear view is hindered by

cargo.

*

brake and remove ignition key before leaving the

vehicle. Choc

* Use extreme caution when cresting hills or when

visibility is limited. Proceed slowly until yo

conditions immediately ahead are safe.

* Keep front wheels straight when c

o

* Do not s

L

* Use extreme caution when descending hills or runn

on loose slippery surfaces. Towing, braking, a

c

* Do not operate vehicle on 15 degree slopes or

s

* Avoid changing direction or making sharp steering

corrections on slopes or rollover m

* If this vehicle begins to tip when crossing a slope, turn

the front wheels downhill to regain stability and

*

wheels slightly uphill and maintain a constant speed to

maintain a straight line of tr

* When descending hills or slopes apply steady

pressure to the foot brake to avoid potential of

freewheeling or runaway.

* Never allow vehicle to coast or

lo

* If your vehicle loses power and stops on a hill,

immediately

d

travel. Do not attempt to turn the vehicle sideways on

the hill or a rollover could result.

* When traveling at night always use your headligh

and reduce speed according to visibility, trail, and terra

conditions.

*

a body of water where depth is unknown. Loss of powe

will occur if the drive belt becomes submerged or wet.

Unnecessary crossing of streams an

e

you must cross, do it at a point where banks are not

steep and proceed at a slow and steady speed.

* Front bumper and brush guards are not

p

implements or damage may result.

*

container that has no screen or filter. Se

o

discharge and do not use Methanol fuel.

* Do not smoke or use e

p

* Always maintain proper tire inflation.

8

* Always disconnect the negative battery terminal befo

making a

re

djustments to the vehicle electrical system or

elding on this vehicle.

ing a

d in this

anual.

at least 15

inutes if battery acid has gotten on them.

fter initial operation and two hours after each tire repair

e

ng.

cle must undergo a Pre-Delivery Inspection

y the Dealer. Listed below is an example of the

ith the Warranty Registration

st

e “Pre-Delivery” steps

efore customer may take possession of the vehicle.

d

erforming the checks.

ealership’s name, signatures of individuals filling in the

r’s signature, and

is re uired to be

ehicle Information

__

w

* Battery fumes are explosive. A spark will ignite battery

fumes. Wear a face shield when charging or jump

battery. Follow all battery safety rules outline

m

* Avoid battery acid spills. Do not get battery acid on

eyes, face, or other body parts. Flush eyes and other

body parts immediately with water for

m

* Always check wheel lug nut torque values two hours

a

and/or replacement. Routinely check lug nut torqu

valves every 100 hours of operation.

* Support this vehicle securely before working beneath.

Chock the wheels to prevent the vehicle from rolli

* Do not shift transaxle unless this vehicle is fully

stopped and the engine is at idle or damage may occur.

Each vehi

b

checklist that is included w

that is to be submitted to Brister’s upon Retail Sale. The

Pre-Delivery Certificate and Warranty Registration mu

be submitted to Brister’s in order to activate the vehicle

warranty.

Pre-Delivery Steps

The dealer is required to complet

b

This information must be filled in and check list checke

off or initialed by individuals p

D

form, seller’s signature, custome

signing dates are also required.

Below is a list of the information that q

ompleted and checked off. c

V

Model No. _______ __

Date ___________

al No. ___________ Seri

Engine Serial No.

ealer Service and Inspection List

charged.

ts/nuts are tightened to 90

l at the dipstick. Add SAE

ark on the dipstick.

nd under seat storage

ck engine for correct RPM. Set to factory

tness.

l is firm and

seat belts are properly fastened

ce.

and

cuting a full lock to lock turn in

ke sure it will engage,

old and release.

D

__

Fully charge battery. Check battery voltage to verify

hat it is fullyt

__ Check fuel valve lever to make sure it is in the

correct position.

__ Check tire pressure to make sure front and rear tires

have 6 psi.

_ Make sure wheel lug bol_

Newton meters (65ft.lbs).

__ Check engine oil leve

10W30 oil if oil is below the full m

*this should be done with seat (a

Tray if equipped) removed

_ Che_

specification if needed.

__ Check tie rods for tigh

__ Check Choke Control. It should move and return

reely. f

_

d

_ Step on foot brake to make sure the peda

oes not go to the floor.

__ Make sure seats and

to the frame.

_ Make sure all safety decals are in pla_

__ Check headlights to make sure they are working

are properly mounted.

__ Inspect air cleaner element. Make certain it is clean

and in place.

__ Inspect the fuel tank to make sure it is properly

installed and that there are no leaks.

__ Check fuel level to make sure there is at least 1/8 of

a tank of gas prior to performing initial starting

operations.

__ Inspect fuel lines to make sure they are properly

installed and that there are no leaks.

_ Check steering by exe_

each direction.

__ Check parking brake to ma

h

9

__ Check throttle control to make sure it moves and

returns freely.

__ Fluid fill and lubrication points have been located and

explained to the customer.

__ Check differential oil level at the differential oil plug.

cleanliness and for

ealer Test Ride List

ng

sponse. Also check neutral start response.

k parking brake to make sure it engages, holds,

nd disengages.

_ Make sure throttle is responsive and returns freely.

sion ride is satisfactorily and

table.

re there are no fuel or petroleum leaks.

gement and

tration form is complete.

d

mer.

ustomer.

_ Fuel transportation and storage procedures have

__ Information on the safety decals have been reviewed

with the customer.

Add 30 weight oil if oil is low.

_ Check overall appearance for

Customer Acceptance List

_

body and molding damage.

Customer initials required where accepted as

successfully completed.

D

__ Check engine for starting, accelerating, runni

smooth, and idling smoothly.

__ Customer has reviewed and understood warranty

policy (ies).

__ Check steering response. There should be no free

play.

__ Customer has inspected the vehicle and it meets

customer satisfaction.

__ Check forward, neutral, and reverse shifting

__ Customer understands the importance of following

the owner’s manual instructions.

re

__ Chec

a

_

__ Make sure the suspen

s

* IMPORTANT NOTICE *

__ Make su

WHEN TRANSPORTING ANY

BRISTER UTILITY VEHICLE

WITH A WINDSHEILD OR COLOR MATCHED

TOP DO NOT EXCEED 55MPH

__Make sure the foot brake has a firm enga

that stopping is straight.

__ Make sure there are no abnormal rattles or

vibrations.

Dealer Delivery to Customer List

__ Warranty regis

__ Owner’s Manual has been delivered to and reviewe

by the customer.

Brister’s Design & Manufacturing Co. LLC

Toll Free PH: 1-866-646-5278

Fax: 1-866-329-5278

__ Engine Manual has been delivered to and reviewed

by the custo

www.bristers.com

__Warranty Policy limits and requirements have been

explained to the c

__ Location and functions of vehicle controls have been

explained.

_

been explained.

__ Transportation of utility vehicle is limited to 55mph,

hen equipped with top and windshield w

10

Section 3 Assembly Instructions

Brister Utility Vehicle Utility Vehicle

Assembly Instructions

ollowing items to be assembled:

Your new Brister Utility Vehicle Utility vehicle should include the f

Qty Item

1 #8 black screw (steering cap)

3 ¼” x 1 ¾” Hex head bolts

7 ¼” nylock nuts

4 ¼” x ¾” carriage bolts

4 ¼” flat washers

8 5/16” x 2” socket head bolts

12 5/16” curved washers

10 5/16” nylock nuts

4 5/16” x 2” hex head bolts

2 5/16” center lock nuts

Qty Item

2 5/8” x 4” Hex bolt

2 5/8” nylock nuts

1 set of keys

1 Steering wheel (with cap)

1 Bumper

2 Rear fenders

2 Rear frame stubs

1 Seat back

1 Cage

1 Cargo Bed with tailgate

11

Section 3 Assembly Instructions

Pre-Assembly Instructions

1) wner’s Manual.

nd assembly parts. Make sure you

ed on the previous page.

o have any questions or problems with your

Brister's Design & Manufacturing Co. LLC product

please call us, 66-646-5278.

Read O

2) Unpack all vehicle a

have everything list

3) If y u

toll free 1-8

Seat / Brushguard Assembly

1) Place seat back frame on vehicle frame tubes.

Insert a 5/16” x 2” socket head bolt through

both bottom joints. The head of the bolt should

be on the outside of the vehicle. Put a curved

washer on the threaded end of the bolt. Place

a 5/16” nylock nut on the bolts but do not

tighten.

2) Place the cage on front vehicle frame tubes

and seat back. Insert a 5/16” x 2” socket head

bolt through all four joints. The head of the

bolt should be on the outside of the vehicle.

Put a curved washer on the threaded end of

the bolt. Place a 5/16” nylock nut on the bolts.

Tighten all 6 nuts (including step 3).

Bumper Installation

1) Align the holes in the front bumper with the

mounting holes in the front frame tubes. Insert

the four 5/16” x 2” bolts through the bumper

bracket and then into the frame tubes. Put a

curved washer on the threaded end of the bolt.

Place a 5/16” nylock nut on the bolts and

tighten.

Steering Wheel Installation

1) Remove the plastic steering column cover by

removing the 3 screws on the bottom with a

5/16” socket. If equipped with top and bottom

steering column covers

2) Turn vehicle steering so that it is pointed

straight forward. Line up holes in steering

wheel with mounting holes so that the center

spoke is pointing down. Install ¼” x 1 ¾” hex

head bolts from the back. Tighten with ¼”

nylock nuts.

3) Install steering cap with #8 black screw.

4) Re-install steering column cover.

12

Cargo Bed Installation

1) Locate rear frame stubs at the rear of frame.

The bed pivot tube on the stub should be at

the top. Insert 5/16” x 2” socket head bolt.

Loosely install 5/16” center lock nut (do not

tighten until after cargo bed is installed)

2) Place the cargo bed on the vehicle and insert a

5/8” x 4” hex head bolt through each pivot

bracket and frame stub tube.

3) Tighten both 5/16” frame stub bolts and nuts.

4) Install the 5/8” nylock nuts on the pivot bolts.

Tighten the pivots and then loosen ¼ turn.

5) Loosen the bed latch pin bolt on the frame just

enough for it to slide in the adjustment slot.

(shown in upper right photo)

6) Close the bed and position the latch pin bolt so

to

prevent rattles. Tighten the latch pin.

that it is at the bottom of the latch slot

7) Fenders installation (if Equipped, no fenders

on TW265) Tilt the cargo bed up. Line up the

holes in the rear fenders with the square holes

in the bed. The raised rectangular surface on

the fender should be completely hidden under

the bed. If not, turn the fender around. Insert

a ¼” x ¾” carriage bolt through the bed and

into the fender. Fasten with a ¼” flat washer

and a ¼” nylock.

Sea a

1) Pl ed to seat base under front seat

t B se Installation

ace tabs attach

frame bar (if equipped into slots in plastic tray), fold

seat base into position. (if equipped The rear tabs

sh

tray)

ould fall into the slots in the rear of the plastic

13

Sec oti n 4 Operating Instructions

General Operation

Start your Brister Utility Vehicle by following the starting

procedures as noted below.

1. Depress brake pedal with your foot and hold.

Pull firmly up on the park brake lever with your

hand until the lever is tight.

2. Place gearshift in neutral

3. Apply choke fully when engine is cold.

4.

engine.

5. Release ignition key to run position and chok

to normal operating position immediately after

engine starts.

Turn ignition key fully clockwise and hold to stop

e

6 Turn ignition key counterclockwise to stop

engine.

easy as driving a car with an automatic

transmission. A simple forward and reverse shifter

provides direction control.

Just turn the key and the 12 volt electric starter provides

safe and easy starting. There is a manual choke control

below the seat for quick cold weather starting. A back-up

tarter mechanism is provided on the engine

ou accidentally leave the key on and run

infinitely variable torque converter

s no clutching. You just shift

vehicle is

go. Never shift

ing is accomplished by simply depressing the brake

n the center console located between the

Driving is as

pull-rope s

st in case y ju

the battery down. The

drive system means there i

into either forward or reverse when the

stopped and press the throttle pedal to

while the vehicle is moving.

rakB

pedal that is located on the floorboard left of the

accelerator. A lever action parking brake control is

mounted o

operator and passenger seats. Depress the button on

the park brake control lever to release the park brake.

Pre-Start Check List

__ Check tire pressure as indicated.

s.

_ All nuts, bolts, screws, and fasteners should be

cked.

_ Turn on headlights to make sure battery has a charge

nd electrical lighting circuit is working.

_ Check tail lights and brake lights. (if applicable)

_ Check park brake to make sure it will engage, hold

nd release.

_ Check steering by executing a full lock to lock turn in

__ Check engine oil level at the dipstick. Add oil as

should be

__ Make sure wheel lug bolts/nuts are tightened to 65ft.

lb

_

che

_

a

_

a

_

each direction.

indicated.

_ Check differential oil level at the differential oil plug._

Add gear lube as indicated.

__ Check fuel valve lever position. Valve lever

ff except when running the engine. o

__ Check fuel level to make sure there is at least 1/8 of a

tank of gas prior to performing initial starting operations.

14

Section 5 Maintenance

Fuel Type

The fuel tank is located under seat.

is 5 Gal.

W-265 & TW265 Fuel capacity is 6.1 Liters

hen filling the fuel tank, place the gear shift in forward

rake, turn off the engine, and

move ignition key. Clean dirt from around the fuel tank

inished, screw

e cap back on securely and wipe up any spilled

aded gasoline with an octane

ting of 87 or higher.

nol, gasoline

fuel system could be

varnish build-up in the fuel system.

dd the correct amount of gas stabilizer/conditioner to

the gas. Follow the gas stabilizer/conditioner

manufacturer’ st results.

See engine o ual for the following:

* Draining the

g fuel line for cracks and leaks.

Engine fuel valve lever.

attention should be paid to

pplicable data that is not duplicated here.

TW11, TW 413, CW11, CW413 Fuel Capacity

C

W

or reverse, set the park b

re

cap, remove cap, and begin filling. When f

th

gasoline. Use regular unle

ra

IMPORTANT: Never use metha

containing methanol, or gasohol containing more than

10% ethanol because the

damaged. Do NOT mix oil with gasoline.

Using a fuel stabilizer/conditioner in the vehicle can

provide benefits such as:

* Keeps gasoline fresh during storage of 90 days or less.

For longer storage, drain the fuel tank.

* Cleans the engine during operation.

* Eliminates gum-like

A

s directions for be

perator’s man

fuel tank.

Checkin*

*

Engine Maintenance

General Information

Detailed instructions and recommendations for break-in

and regular maintenance are specified in the engine

operator’s manual. Engine warranty is backed by the

engine manufacturer. Please refer to engine

manufacturer’s manual for engine servicing, lubricating

oil levels, oil quality and viscosity recommendations, bolt

orques, etc. Specialt

a

Engine Fuel Valve Lever

fer to Figure 5-1

closes the passage

tween the fuel tank and carburetor. Leave fuel valve

n use

Re

The engine fuel valve opens and

be

lever in the OFF position when the engine is not i

to prevent carburetor flooding and reduce possibility of

fuel leakage into the cylinder cavity and engine oil

reservoir. Turn fuel valve lever to the ON position when

running the engine.

FUEL VALVE

Figure 5-1

15

Section 5 Maintenance

* Foam element – Clean foam element with

detergent in warm water or in a nonflammable solvent.

Do not wring element. Squeeze excess cleaning fluids

out. Allow time for the element to dry and then soak it

ith clean engine oil. Squeeze excess oil out. Excess oil

ft in the filter will cause engine to smoke briefly when

rst started.

efore installing the filter elements to make sure they

en damaged during cleaning. Never run an

w

le

fi

B

have not be

engine without the filters installed.

Figure 5-2

Spark Plugs

HONDA

NGK BPR6ES

CHAMPION RN9YC

UTOLITE 4263 / 63

UBARU

A

DENSO W20EPR-U

S

RLH6C

NGK BR6HS

HAMPION C

Air Filter Elements Replacement Parts

Description Part No.

Honda

Paper Filter Element 17210-ZE3-000

-010

e monthly for cracks,

ge. Replace immediately if any

amage is suspected.

Honda

Foam Filter Element 17210-ZE3

Refer to Figure 5-2

Subaru

Paper & Foam Element (265cc) 279-32607-07

Fuel Hose – Inspect fuel hos

leaks or other dama

d

16

Section 5 Maintenance

Engine Oil

A general description for engine oil maintenance,

recommendations, and capacities is provided below

See Eng

.

ine Operator’s Manual for a detailed description.

Note:

eng

Note:

illing of oil level can cause loss of

power, engine damage and void engine warranty.

Engin

Ref

REMOV

EAS

ap/dipstick location: At front end of engine

of

J, SL or Equivalent

Honda Engine Oil Capacity: 1.16 US qts. /1.1 liters

Engine Oil Maintenance Schedule

* Check oil level after each use.

* Make first oil change after the first month of operation

or at 20 hours of operation (whichever comes first).

* Make all subsequent oil changes every 6 months or

every 100 hours of operation (whichever comes first).

Engine Oil Level Check

Refer to Figure 5-4

Check engine oil daily with filler cap/dipstick located at

1. Park Vehicle on a level surface, set park brake,

turn off ignition switch, and remove switch key.

2. Remove filler cap/dipstick and wipe it clean.

3. Insert and remove dipstick without screwing it

into the fill neck. Check oil level shown on

ly.

herefore,

rain used engine oil while engine is still warm as

llows:

on a level surface, set park brake,

turn off ignition switch, and remove switch key.

tch

and then

reinstall and tighten drain plug securely.

at is

Running engine low on oil can cause

ine damage and void engine warranty.

Overf

e Oil Fill and Drain Locations

er to Figure 5-4

E SEAT (and plastic tray if equipped) FOR

Y ACCESS

* Filler c

* Drain plug location: At rear end of engine

Type of Lubrication: SAE 30, with API classification*

S

*

* Subaru Engine Oil Capacity: 1.1 US qts. / 1.0 liters

* Quantity: Fill oil to outer edge of oil fill hole.

the engine rear end as follows:

dipstick.

4. Fill to edge of oil fill hole with recommended oil

when oil levels are low.

5. Replace filler cap/dipstick and tighten secure

Engine Oil Change

Warms oil drains quickly and completely. T

d

fo

1. Park vehicle

2. Place a suitable container below engine to ca

used oil. Remove filler cap/dipstick and drain

plug.

3. Allow used oil to drain completely

4. Dispose of used motor oil in a manner th

compatible with the environment. Do not throw

used oil in the trash. Do not pour it on the

ground, or down a drain.

5. Fill oil to the outer edge of the oil fill hole with

recommended oil. Engine must be level when

filling.

6. Replace filler cap/dipstick and tighten securely.

NOTE:

TO DRAIN OIL REMOVE REAR OIL DRAIN PLUG

Engine Oil Drain, Fill & Check Locations

Figure 5-4

17

Section 5 Maintenance

Transaxle Oil

A general description for transaxle oil maintenance,

endations, and capacities is provided below.

xle oil can

Oil Type, Fill, and Drain

Ref

* Fil p

* Dr

* Ty o

* Transa

Transa

* Ch

leakage

* Check l every 6 months or every 200

hou w

This ccomplished by Parking vehicle on a level

surf ce, set park brake, turn off ignition switch, and

remove switch key, using a clean long bladed screw

driv r hole until it

touch e the screw

There should be approximately 2.1/4” to 2.1/2” of

le on screw driver. Refer to Figure 5-5A

Change transaxle oil once a year or every 600 hours

hichever comes first).

recomm

NOTE:

Running vehicle low on transa

nd void warranty.

damage transaxle a

Transaxle

er to Figure 5-5

l ca location: At rear left hand side (See arrow)

ain plug location: At bottom center of transaxle.

pe f Lubrication: SAE 30W oil.

xle Lubrication Capacity: 20 oz.

xle Oil Maintenance Schedule

eck transaxle housing for damage and possible oil

after each use.

transaxle oil leve

rs ( hichever comes first).

can be a

a

er (or similar object) insert into fille

es the bottom of gear case. Remov

driver.

il visibo

*

(w

Transaxle Oil Change

Refer to Figure 5-5B

Warm oil drains quickly and completely. Therefore, drain

used transaxle oil while transaxle housing is still warm

as follows:

. Park vehicle on a level surface, set park brake,

turn off ignition switch, and remove switch key.

. Place a suitable container below the transfer

case to catch used oil. Remove fill cap and drain

plug.

. Allow used oil to drain completely and then

reinstall drain plug and tighten it securely.

transaxle case oil in a manner

ment. Do not

throw used oil in the trash, pour it on the ground,

or down a drain.

5. Fill transaxle housing with 20 oz. SAE 30W oil.

6. Replace fill cap and tighten securely.

1

2

3

4. Dispose of used

that is compatible with the environ

Figure 5-5B

Figure 5-5A

18

Section 5 Maintenance

Drive Belt

The dive belt is considered a wearable item.

Replacement intervals depend on vehicle use and

environment. If your belt is slipping you may need to

replace it.

1. P brake,

place shifter in Neutral, turn off ignition switch,

and remove switch key.

2. Remove the upper belt covers. (It is not

tom cover.

own in

ark vehicle on a level surface, set park

necessary to remove the bot

3. “Walk” the belt off of the rear pulley as sh

Figure 5-6.

Figure 5-6

4. Install the new belt on the front pulley first and

“walk” it onto the rear pulley.

5. Reinstall the belt guards. Figure 5-7.

rds may

void your warranty.

Attention: Failure to reinstall the belt gua

Figure 5-7

19

Section 6 Troubleshooting

Fuel in the Cylinder Cavity

In the event that the fuel valve is left open while

tran o ter Utility Vehicle it is

pos e cylinder

cav l not start. With

the in will feel like it

has “l per steps to follow if

your Brister ine seems to have fuel in

the cylinde

sp rting or towing this Bris

sible that fuel has leaked down into th

I lity. f this has occurred the engine wi

gine cyl der cavity full of fuel the en

ocked pro up”. Below are the

Utility Vehicle eng

r cavity.

Use EXTREME CAUTION when

y

rk Vehicle on a level surface, set park brake,

k

ch

ray

5.

aution: This gasoline spraying out of the

ylinder cavity is very flammable, use extreme

aution and make sure there are no sparks or

ames nearby.

6. epeat step 3 until only air escapes out of the

park plug hole.

7. roperly replace the spark plug back into the

r head, move the vehicle away from any

pilled fuel. If there is fuel on the vehicle itself,

performing the activity below.

Gasoline is EXTREMELY FLAMABLE!

1. Move the vehicle to a well ventilated area, awa

from sparks or flame.

2. Pa

turn off ignition switch, and remove switch key.

3. Next, remove the wire connected to the spar

plug. And remove the spark plug from the

engine. (See Figure 6-1) (Spark Plug Wren

supplied with Operator’s Manual)

4. WARNING: Stand away from the spark plug

hole when performing step 5. Fuel can sp

several feet.

Wearing eye protection, slowly pull the recoil

start grip handle (See Figure 6-2) in an upward

motion. This should force the fuel out of the

cylinder cavity through the spark plug hole.

C

c

fl

R

s

P

cylinde

s

allow for it to evaporate before continuing.

8. Connect the plug wire. Your Brister Utility

Vehicle is now ready to start.

www.bristers.com

Figure 6-1

Figure 6-2

20

Page is loading ...

BRISTERS Chuck Wagon User manual

This manual is also suitable for

BRISTERS Chuck Wagon User manual

Other documents